Bicycle Saddle, Saddle Pad, and Method for Producing a Bicycle Saddle or Saddle Pad

ABSTRACT

The invention relates to a bicycle saddle having a saddle shell, on the underside of which a frame is arranged. A saddle pad is arranged on the upper side of the saddle shell. According to the invention, the saddle pad has two padding elements for improved comfort, wherein in a preferred embodiment the inner padding element is made of TPU (thermoplastic polyurethane).

The invention relates to a bicycle saddle, as well as to a saddle pad.The invention further relates to a method for producing a bicycle saddleor a saddle pad.

Bicycle saddles have a saddle shell whose lower side is usuallyconnected with a saddle frame. A saddle pad is arranged on the upperside of the saddle shell. Typically, saddle pads are made of foamedmaterial, such as PU foam. The saddle pads are glued onto the upper sideof the saddle shell. Such in particular foamed saddle pads have gooddamping characteristics. However, in particular during longer trips, thepad may be compressed such that especially the seat bones of the userpress on the upper side of the saddle shell so that pressure marks areformed. The reason for this is that the so-called rebound of such saddlepads is small. Therefore, it is known to provide gel pads in the seatregion, i.e. in the rear region of the bicycle saddle in which the seatbones of the user are arranged. Such insert elements filled with agelatin- or gel-like material are inserted into recesses in the saddlepad. Thereafter, the saddle pad with the inserted gel elements arecovered with a textile element or the like. However, such gel elementsonly lead to a limited improvement of the sitting comfort, since the gelelements merely cause a better distribution of the forces occurring.

It is an object of the invention to provide a bicycle saddle, as well asa saddle pad with improved sitting comfort. Further, it is an object ofthe invention to provide a corresponding production method.

The object is achieved, according to the invention, with a bicyclesaddle as recited in claim 1 or claim 17, as well as with a saddle padas recited in claim 25. The object regarding the production method isachieved with the features of claim 28.

A bicycle saddle comprises a saddle shell typically made of hard plasticmaterial. A saddle frame is arranged at the lower side of the saddleshell. The saddle frame serves for connection with the saddle supporttube, wherein the saddle frame may also be integrally formed with thesupport tube. With common saddles, the saddle frame is an element madeof metal bars that is connected both with a saddle tip directed in thetraveling direction and with the rear of the saddle. Other connectionsbetween the saddle shell and the saddle frame or a connecting element tothe saddle support tube corresponding to the saddle frame are known aswell. A saddle pad is arranged on the upper side of the saddle shell.The same may be glued onto the upper side of the saddle shell or may beconnected directly with the upper side of the saddle shell alreadyduring manufacturing, using corresponding manufacturing techniques.

With bicycle saddles according to the invention, the saddle padcomprises at least two pad elements. The pad elements serve inparticular to dampen the movements occurring when riding a bicycle, aswell as to support the user in the most comfortable manner possible. Thepad elements may also be made of different materials, the correspondingelements serving in particular for dampening and support.

In a first bicycle saddle according to the invention, the saddle padcomprises at least one inner pad element and at least one outer padelement. According to the invention, the inner pad element is at leastpartly enclosed by the outer pad element. In this respect it ispreferred that the inner pad element is enclosed by the outer padelement by overmolding or foaming the latter around the former. Thereby,it is possible in particular to make a connection between the outer andthe inner pad element during the production off the outer pad element,since a corresponding material bond can be realized during theovermolding or foaming process.

It is particularly preferred that the inner pad element is arranged suchthat it is arranged on the upper side of the saddle shell. The inner padelement thus preferably rests on the upper side of the saddle shell orcontacts the same. In particular, the inner pad element is connectedwith the saddle shell, wherein a connection may be made by gluing,locking or other types of fixation. According to the invention, it isthus preferred that an outer pad element is arranged at least in partabove the inner pad element or that the outer pad element surrounds theinner pad element on the upper side in particular to a large extent.Thus, it is possible to combine two different materials. This is done inparticular in the seat region. The material of the outer pad element canbe selected such that it provides for good damping, i.e. that it is assoft as possible and designed in a manner comfortable to the user. Theinner pad element may then be somewhat more solid and may preferablyhave good rebound characteristics, i.e. good supporting characteristics.

Preferably, a lower side of the inner pad element is in surface contactwith the upper side of the saddle shell. In particular, the inner padelement is surface-connected with the upper side of the saddle shell, inparticular glued or fixed in another manner.

In another embodiment, the inner pad element may have protrusions thatcontact the upper side of the saddle shell. In particular, these areprotrusions formed as feet or webs so that there is no surface-contactbetween the inner pad element and the upper side of the saddle shell,but only the protrusions contact the saddle shell. This has theadvantage that in the regions between the inner pad element and theupper side of the saddle shell, a further pad element, in particular ofanother material, can be introduced. Specifically, this is the samematerial as the material the outer pad element is made of, wherein it ispreferred, in particular, that the material is a foamed or foamablematerial.

In a particularly preferred embodiment, the inner pad element has atleast one retaining protrusion. With the inner pad element mounted, theretaining protrusion extends into at least one recess in the saddleshell. The recess may in particular be at least one indentation in theupper side of the saddle shell. The at least one retaining protrusionextending into the recess or indentation serves to define the positionand possibly also to fix the inner pad element on the saddle shell. Inthis respect, it is particularly preferred that the recess is formed asa continuous opening in the saddle shell. Thereby, the manufacture ofthe saddle shell or the recess is already simplified. In thisembodiment, the at least one retaining protrusion is preferably designedsuch that it extends through the opening. This is advantageous in thatthe provision of an inner pad element is visible from outside whenlooking at the saddle from below. Further, such a design of the recessas a continuous opening is advantageous, since the retaining protrusioncan thereby be used in a simple manner to fix the inner pad element.

Particularly with respect to its design and dimensions, the retainingprotrusion is formed such that it is possible to press it into theopening with a certain resistance, so that it is possible to fix theinner pad element in the opening by means of the retaining protrusion,e.g. due to a deformation of the retaining protrusion and/or thefriction between the retaining protrusion and the edge of the opening.Preferably, the retaining protrusion has at least one extension that maye.g. of a bead-like design. The at least one extension serves to fix theinner pad element on the saddle shell or in the opening in the saddleshell. In particular, the at least one extension is designed such that,in the pressed-in or mounted state, the extension engages behind a lowerside of the saddle shell. Thus, the extension is somewhat larger thanthe opening in this region. In particular, the extension may also be ofannular shape, so that a very good fixation of the inner pad element onthe saddle shell is possible by pressing the retaining protrusion intothe opening.

In a preferred embodiment of the bicycle saddle, the at least one padelement is arranged in the seat region, i.e. in the rear part of thebicycle saddle. This is the region in which the user sits on the saddleand in which in particular the seat bones are located. Likewise, theinner pad element or an additional inner pad element may be arranged inthe center region or perineal region of the bicycle saddle. This innerpad element may in particular be thinner, since the pressure load inthis region is increased in particular only in sitting positions inwhich the user is bent forward. It is preferred that an inner padelement is designed such that it is arranged both in the seat region andin the center region. In particular, such a pad element is formedintegrally. In this respect it is preferred that such a n inner padelement is thinner in the center region than in the seat region.Thereby, a very good improvement of the comfort is achieved.

In a particularly preferred embodiment, the inner pad element isentirely enclosed by the outer pad element which is made in particularby foaming. In this respect it is preferred that a lower side of theinner pad element is not or only partly enclosed by the outer padelement, since, in a preferred embodiment, this side of the inner padelement contacts the upper side of the saddle shell.

Preferably, a rear region of the inner pad element is not enclosed by anouter pad element. The rear region is a region of the inner pad elementthat is directed rearward with respect to the traveling direction.Preferably, the inner pad element is arranged or designed such that therear region of the inner pad element is arranged at a rear side of thesaddle shell, in particular in the region of the rear edge of the saddleshell. Not surrounding this region of an inner pad element with an outerpad element has, in particular, the advantage that the inner pad elementis visible and, as such, a user can immediately realize that this is abicycle saddle with a plurality of pad elements, in particular made fromdifferent materials.

In another bicycle saddle of the present invention, again, a saddleshell is provided at the lower side of which a saddle frame and at theupper side of which a saddle pad is arranged. Again, the pad elementcomprises at least two pad elements. In this invention, which is anindependent invention, the saddle pad has a main pad element and anauxiliary pad element. The main pad element is connected with an upperside of the saddle shell. The connection may be realized e.g. by gluing,but also directly by the production method. The main pad element has arecess or indentation in which the auxiliary pad element is arranged.The auxiliary pad element placed or inserted into the recess is gluedin, for example. The main pad element may have a plurality of recessesin which one auxiliary pad element is arranged, respectively.

In a particularly preferred embodiment of this bicycle saddle, the mainpad element is not covered or spanned with a textile material. However,it is preferred that the auxiliary pad element is provided with atextile material at least on the upper or outer side in particular toreduce friction.

The at least one auxiliary pad element may be arranged in a seat regionor in a center region. It is particularly preferred to arrange suchauxiliary pad elements in outer regions of the center region. These areregions which are in contact with the inner sides of the thighs oragainst which the inner sides of the thighs rub during pedaling.

Corresponding to the above described inner pad element, the auxiliarypad element is preferably designed such that an auxiliary pad elementarranged in the seat region is thicker than an auxiliary pad elementarranged in the center region of the saddle. Specifically, either twoseparate auxiliary pad elements are provided or an auxiliary pad elementis provided that is correspondingly integrally formed and covers bothregions. If corresponding auxiliary pad elements are provided inparticular in both the left and the right outer region of the centerregion, these pad elements may also be connected with an auxiliary padelement arranged in the center region or may be integrally formed.

A pad element of the present invention may in particular also bedesigned such that it is arranged both in the seat region and in thecenter region, wherein the pad element may again be formed by twoconnected auxiliary pad elements or one integrally formed pad element.In the center region the auxiliary pad element is preferably thinnerthan in the seat region.

It is preferred that, in particular for a reduction of friction and forincreasing the comfort, the at least one auxiliary pad element isspanned with an in particular textile material at least on its outerside. Here, in particular such material is used that is suited andconventionally used for spanning saddle pads of bicycle saddles.

In a preferred embodiment, the auxiliary pad element is glued into thecorresponding recess or indentation of the main pad element.

In a particularly preferred embodiment, the inner pad element or themain pad element is formed as an elastomer body. In particular, theelastomer body preferably includes thermoplastic elastomers (TPE).Preferably, foams are used, such as PU foams. In particular, closed-cellfoams are preferred. The inner pad element or the main pad element inparticular includes TPU (thermoplastic polyurethane) and, as isparticularly preferred, is made from this material. The materialproduced by BASF under the product name “Infinergy” is particularlysuited for this purpose. Methods for producing TPU are described e.g. inEP 692 510, WO 00/44821, EP 11 74 459 and EP 11 74 458. Further, it ispreferred that the inner pad element or the main pad element is madefrom EVA (ethylene vinyl acetate) or the main pad element is made from amaterial that includes EVA. Further, EPP (expanded polypropylene),thermoplastic elastomers (TPE) and EPE (expanded polyethylene) may beused as materials. A combination of these materials or a combination ofthese materials with other materials is also possible, e.g. in amulti-layered structure. In particular, mixtures with co- or terpolymersmay also be used. Thereby, different damping and movementcharacteristics of the seat cushion can be obtained. It is also possibleto provide a higher compaction of the corresponding materials indifferent regions, so that the damping and movement characteristics canbe influenced thereby.

Moreover, a thermoplastic elastomeric spherical foam is suited as amaterial for the elastomer body. Such a foam is offered by Sekisui underthe product name “ELASTIL”. In particular, this is a closed-cell foam.In a preferred embodiment, according to the invention, the elastomerbody comprises a thermoplastic elastomeric spherical foam, such as inparticular Elastil, or is made from the same. A combination with theother materials described, which are suitable for forming the elastomerbody, is also possible.

Another well suited material for forming the elastomer body is apolyester-based PU material. In this respect, the material offered byBASF under the product name “Elastopan” is particularly suited.Preferably, the elastomer body includes such a material or is madetherefrom, while it is again possible to combine this material withother materials described.

It is particularly preferred that the elastomer body includes one or aplurality of particulate foams and is, in particular, made from one or aplurality of particulate foams. As a base material, E-PTU, EPP, EPS, EPEor similar foams are particularly preferred. Generally, particulatefoams are formed by small spheres of the expanded base material. Theseparticles formed as spheres or other bodies are given their final shapein a tool, such as a casting mold or the like, using temperature and,possibly, water vapor. In particular, particulate foams have theadvantage that they have a low density, a good heat/cold insulation andgood damping characteristics.

In a particularly preferred embodiment, the elastomer body, i.e. theinner pad element or the main pad element, has an elasticity module of0.1 to 10 MPa, in particular 0.1 to 5 MPa and particularly preferred 0.1to 1.0 MPa. The particularly preferred material “Infinergy E-TPU” has amodulus of elasticity between 0.1 and 0.5 MPa.

Further, it is particularly preferred that the elastomer body has a lowweight due to its low density. Specifically, the elastomer body has adensity of less than 1 g/cm3, particularly preferred less than 0.5g/cm3, and in particular less than 0.2 g/cm3. One of the particularlypreferred materials, the material Elastil, has a density in a range from0.05 to 0.2 g/cm3.

The rebound behavior of the inner pad element or the main pad elementpreferably is in a range of preferably more than 30%, in particular morethan 40% and particularly preferred more than 50%.

The outer pad element or the auxiliary pad element is preferably made ofa foamable material, in particular foamed plastic material. PU foam isparticularly suited.

The saddle shell preferably includes PP, PA6 or PA12 as a material or ismade of this material. According to the invention, the modulus ofelasticity of the saddle shell is in a range from 1000 to 10000 MPa,preferably in a range from 2500 to 6000 MPA, and particularly preferredin a range from 3000 to 5000 MPa. The use of PP (E-modulus: 1100 to 1450MPa), PP GF20 (E-modulus ca. 2900 MPa), and/or PA 6 GF15 (E-modulus:4500 to 6500 MPa).

A further independent invention relates to a saddle pad for a bicyclesaddle, the saddle pad of the invention being suited in particular forthe above described bicycle saddles.

The saddle pad of the invention comprises to pad elements. In apreferred embodiment, a first pad element is made of TPU and/or EVAand/or EPP and/or TPE and/or EPE or comprises that material. In thisrespect, the first pad element may also be made of combinations of thesematerials or of a combination with other materials. The first padelement is thus made of a material which, in a preferred embodiment,corresponds to the material the inner pad element or the main padelement is made of. The second pad element is a pad element of foamablematerial. It is particularly preferred that this is a PU foam. Thesecond pad element is thus made corresponding to the preferredembodiment of the outer pad element or the auxiliary pad element orcomprises the corresponding material.

In a particularly preferred embodiment, the first pad element is atleast partly enclosed by the second pad element, in particularovermolded or encapsulated with foam.

The invention further relates to a bicycle saddle with such saddle pad.

For manufacturing the saddle pad, it is preferred, according to theinvention, to first fix a first pad element of TPU or another materialdefined above in a casting mold. In the next method step, material isintroduced into the casting mold for forming the second pad element, thematerial of the second pad element particularly being PU foam or one ofthe other material defined above. In a preferred embodiment, the firstpad element is clamped in the casting mold. Thus, the first pad elementcontacts e.g. a cover and an opposite bottom element of the castingmold. During the subsequent introduction of the material for the secondpad element and the subsequent foaming of this material, a saddle pad isthus obtained, in which the first pad element is not enclosed orfoam-encapsulated by the second pad element in the two regions in whichit contacts the casting mold. Thereby, it is in particular possible toproduce such saddle pads as described with respect to the bicyclesaddles of the invention.

In a preferred embodiment, the first pad element is prefabricated. Forthis purpose, the first pad element is preferably prefabricated in aseparate mold. The prefabricated first pad element is then placed intothe casting mold.

In a preferred development of the method for producing the saddle pad, asaddle cover or a saddle pad cover may be placed in the casting moldbefore inserting the first pad element. The cover is in particular madeof a textile material and, in a particularly preferred embodiment, isretained in the casting mold by vacuum. Thereby, an extremely smoothsurface may be realized.

In another method for producing a bicycle saddle, which is anindependent invention, a first step provides that an inner pad elementis fastened on an upper side of the saddle shell. Thereafter, the saddleshell is placed in a casting mold together with the inner pad elementfastened thereon. In the subsequent step, a material is introduced intothe casting mold to form an outer pad element. Here, pad elements arepreferably produced by foaming this material in the casting mold. Byfastening the inner pad element on the saddle shell, it is in particularpossible to provide a space between the upper side of the inner padelement, i.e. the upper side of the pad element averted from the upperside of the saddle shell, and an inner side of the casting mold. Thematerial of the outer pad element enters into the same, so that theinner pad element is at least partly enclosed, in particular overmoldedor foam- encapsulated, by the outer pad element.

The inner pad element may also be designed or formed such that the samecontacts the inner side of the casting form in individual regions, e.g.in the region of a rear side of the pad element. As a result, the innerpad element is not enclosed by the outer pad element in this region.

The inner pad element, which is preferably made of TPU, is preferablyprefabricated. It is particularly preferred that the inner pad elementhas a retaining protrusion as described above. The same may be pressedinto a recess of the saddle shell which is formed in particular as acontinuous opening. Thereby, as described above with reference to thebicycle saddle, it is possible to arrange or fix the at least one innerpad element on the saddle shell in a simple manner.

In a preferred embodiment, the saddle shell is placed into the castingmold together with the at least one inner pal fastened thereon, theupper side being directed downward. This is advantageous for theintroduction of the material of the outer pad element that may inparticular be poured in or inserted. In this respect, it is particularlypreferred that the inner pad element is fixed on the upper side of thesaddle shell in order to avoid the inner pad element from falling off orsinking down in the casting mold during the production process.

In a further preferred embodiment, the saddle cover is placed into thecasting mold, before the saddle shell is placed into the casting mold.In particular, this is a saddle cover of textile material or anothermaterial conventionally used for spanning saddles. In order to realize asmooth surface, it is preferred that the saddle cover is retained in thecasting mold by vacuum.

Typically, the saddle shell is already connected with the saddle frameprior to the production of the bicycle saddle, without this beingnecessarily so.

The method of the present invention is developed in an advantageousmanner, in particular as described above with reference to the bicyclesaddle having an inner and an outer pad element.

In a preferred embodiment, the production of the bicycle saddle with amain and an auxiliary pad element is effected such, according to theinvention, that the saddle shell is placed into a casting mold. Theinner surface of the casting mold is designed such that it forms therecess in the main pad element. In the next step, the material for themain pad element is introduced, the material preferably being TPU. Afterthe production of the main pad element which is fixedly connecteddirectly with the upper side of the saddle shell, the additional padelement can be arranged in the recess. The additional pad element whichis preferably made of foamed material and is possibly spanned with asaddle or pad cover, is preferably produced in a separate process. Themethod of the present invention for producing the bicycle saddle with amain pad element and an auxiliary pad element is preferably developed inan advantageous manner, as described above with reference to thecorresponding saddle.

The use of TPU as the pad material has the basic disadvantage that thematerial is made from a plurality of sphere-like or sphericalstructures. As such, the surface of the material is relatively rough oruneven. By surrounding, in particular foam-encapsulating, the TPU with afoamable material, this unevenness can be smoothed. In additions, byproviding a corresponding outer material and/or saddle cover, a surfacewith less friction can be made.

When using TPU for the main pad element, the same is visible in largeparts of the saddle, wherein, in this case, an auxiliary pad element offoamed material or the like is provided in particular in the seatregion, so that the comfort is improved.

The inventions will be explained in more detail hereinafter withreference to preferred embodiments and to the accompanying drawings.

In the FIGS.:

FIG. 1 is a schematic top plan view of a first preferred embodiment of abi cycle saddle,

FIG. 2 is a schematic sectional view along the line II-II in FIG. 1,

FIG. 2a is a schematic sectional view through an alternative embodimentto FIG. 2,

FIG. 3 is a schematic sectional view along line II-II through analternative embodiment,

FIG. 4 is a schematic top plan view on another embodiment of a bicyclesaddle,

FIG. 5 is a schematic sectional view along line V-V in FIG. 4,

FIG. 6 is a schematic top plan view on another embodiment of a bicyclesaddle, and

FIG. 7 is a schematic sectional view along line VII-VII in FIG. 6.

In the different preferred embodiments of the inventions describedhereinafter, similar and identical parts are respectively identified bythe same reference numerals.

The bicycle saddles illustrated each have a saddle shell 10. A saddleframe 14 is connected with a lower side 12 of the saddle shell 10. Herethe saddle frame 14 is formed in particular by two metal bars of whichthe rear bar is visible in sectional views (FIGS. 2, 3, 5 and 7). In theregion of a saddle tip 16, the two bars are fixed in a protrusion 18 ofthe saddle shell 10. In the region of the rear side 20 of the saddle,the two bars of the frame 14 are each fixed separately in a protrusion22 of the saddle shell 10.

On an upper side 24 of the saddle shell 10, a saddle pad 26 is arrangedwhich is built-up differently in the different embodiments.

In the first preferred embodiment (FIGS. 1 and 2), the saddle pad 26 hasan inner pad element 28 as well as an outer pad element 30 surroundingthe inner pad element 28 substantially completely. The inner pad element28 is preferably made of TPU and the outer pad element 30 is made of aPU foam. The inner pad element 28 contacts the upper side 24 of thesaddle shell 10 by a flat lower side 32. Possibly, the inner pad element28 is connected with the upper side 24 of the saddle shell 10 by gluing.The PU foam serves to produce the outer pad element 30 which surroundsall sides of the inner pad element 28 except for the lower side 32.Possibly, the inner pad element 28 may also be arranged such that theouter pad element 30 does not surround the same e.g. in the region of arear side 34 so that the inner pad element 28 is visible in this region.

In the embodiment illustrated in FIGS. 1 and 2, the inner pad element 28is arranged in a seat region 36 of the saddle. Contiguous to the seatregion 36 are a center region 38 as well as a saddle tip 40. In thisembodiment, only a saddle pad of PU foam is arranged both in the centerregion 38 and in the region of the saddle tip 40, so that only the outerpad 30 is provided in this region.

In an alternative embodiment in FIG. 2a , similar and identical partsare identified by the same reference numerals. The only differencebetween the embodiments illustrated in FIG. 1 and FIG. 2a is in thedesign of the inner pad element 28. In the design shown in FIG. 2a , theinner pad element 28 has an upward extending protrusion 20. Theprotrusion 29 is preferably formed integrally with the inner pad element28. In this embodiment, an upper side 31 of the protrusion 29 is notcovered by the outer pad element 30 so that the upper side 31 of theprotrusion 29 is well visible to the user.

In an alternative embodiment (FIG. 3), the inner pad element 28 isdesigned such that it has protrusions or feet 42 directed towards theupper side 24 of the saddle shell 10. An inner pad element 28 of suchdesign is connected, e.g. glued, with the upper side 24 of the saddleshell 10 in particular via the feet 24. By providing the feet it ispossible to form regions 44 beneath the inner pad element 28. These maybe designed as cavities or may also be filled with the foam in thematerial of the outer pad element 30.

With the embodiment illustrated in FIG. 3, the damping and reboundcharacteristics of the saddle can be varied in the seat region 36.

In an alternative embodiment, the inner pad element 28 illustrated inFIG. 3 can also have a protrusion 29 similar to the embodimentillustrated in FIG. 2 a.

The inner pad element may also, as illustrated in FIG. 5, be designed asan inner pad element 46 or may have another shape. In the seat region36, the inner pad element 46 is designed similar to the inner padelement 28 illustrated in FIG. 2. In addition, the inner pad element 46with the part 48 arranged in the seat region is provided with a part 50of the inner pad element 46 in the center region 38. Both parts 48, 50of the inner pad element 46 are formed integrally. The part 50 of theinner pad element 46 is thinner or has a lower height than the part 498arranged in the seat region 48.

A retaining protrusion 54 is arranged on a lower side 52 of the innerpad element 46. The retaining protrusion 54 is connected with anextension 56 which in the embodiment illustrated is designed as a bead.In the embodiment illustrated, the retaining protrusion 54 iscylindrical and the extension 56 is designed as an annular bead. In thesaddle shell 10, a recess or opening 58 is arranged which in theembodiment illustrated is continuous. For fixing the inner pad element46, it is thus possible to press the retaining protrusion 54, togetherwith the bead 56, through the opening 58 in FIG. 5 from above. Owing tothe bead 56, which has a larger dimension than the opening 58, a secureretention of the inner pad element 46 is achieved.

For producing the bicycle saddles illustrated in the FIGS. 1 to 5 ordescribed above, the corresponding inner pad element 28 or 46 isproduced in a corresponding mold in a first step. The inner pad element28, 46 is preferably made of TPU and in particular the material sold byBASF under the trademark “Infinergy”. In the next step, the inner padelement 28, 46 is connected with or fixed to the upper side 24 of thesaddle shell 10. In the embodiments illustrated on FIGS. 1 to 3, this iseffected e.g. by gluing. In the embodiment illustrated in FIGS. 4 and 5,the connection is made by pressing the retaining protrusion 54 into theopening 58. In the next step, the saddle shell is placed into a castingmold together with the inner pad element 28, 46 fastened thereto andtogether with the frame 14 provided on the outer side. The placing intothe casting mold is effected such that the saddle frame is directedupward. Thereafter, the material for producing the outer pad element 30is filled into the casting mold and is foamed. Due to the saddle beingplaced into the casting mold with the saddle frame directed upward,filling in the material for the outer pad element 30 is possible in asimple manner. By fixing the inner pad element 28, 46 to the saddleshell 10, it is ensured that the element remains in contact with theupper side 24 of the saddle shell 10.

Possibly, prior to placing the saddle shell into the casting mold, thesame can be lined with a saddle cover. The saddle cover is fixed in thecasting mold preferably by means of vacuum so that a smooth surface isrealized.

In the embodiment illustrated in FIGS. 6 and 7, a main pad element 60 isconnected with the upper side 24 of the saddle shell 10. In this case,the main pad element 60 is preferably made of TPU. The main pad element60 can be produced in a separate mold and be glued on the upper side 24thereafter. Likewise, it is possible to arrange the material forproducing the main pad element 60 in a mold together with the saddleshell 10. When TPU is used to produce the main pad element 60, the rawmaterial is exposed to vapor. Therefore, it is advantageous that thesaddle shell 10 has small passage openings for introducing vapor. Theshape main pad element 60 is designed such that at least one recess 62is provided in the seat region 36. In the center region 38, one furtherrecess 64 (FIG. 6) is provided on either side. Auxiliary pad elements66, 68 are arranged n all recesses 62, 64. The auxiliary pad elements66, 68 are made in particular of PU foam and are covered with a saddlecover material preferably on the outer sides. Thus, by arranging theauxiliary pad elements 68, friction is reduced in particular at thesides in the center portion 38. By the combination of the two padelements 60, 66, a good damping and a good rebound behavior are achievedin the seat region 36.

As an alternative, it is possible in all above described embodiments toproduce the saddle pads 26 independently of the saddle shell. Thecorresponding saddle pads which comprise at least two different padelements, can then be e.g. glued on the upper side 24 of the saddleshell 10.

1. A bicycle saddle comprising a saddle shell, a saddle frame connectedwith a lower side of the saddle shell, and a saddle pad arranged on anupper side of the saddle shell, the saddle pad comprising at least twopad elements, wherein an inner pad element is enclosed at least in partby an outer pad element.
 2. The bicycle saddle of claim 1, wherein theinner pad element is arranged on the upper side of the saddle shell. 3.The bicycle saddle of claim 1, wherein a lower side of the inner padelement is in surface contact with the upper side of the saddle shell.4. The bicycle saddle of claim 1, wherein the inner pad element hasprotrusions in contact with the upper side of the saddle shell.
 5. Thebicycle saddle of claim 1, wherein the inner pad element comprises atleast one retaining protrusion extending into a recess of the saddleshell.
 6. The bicycle saddle of claim 5, wherein the recess is formed asa passage opening in the saddle shell.
 7. The bicycle saddle of claim 5,wherein the retaining protrusion extends through the passage opening. 8.The bicycle saddle of claim 5, wherein the retaining protrusion has atleast one extension configured for fixing the inner pad element on thesaddle shell.
 9. The bicycle saddle of claim 8, wherein the at least oneextension engages behind the saddle shell.
 10. The bicycle saddle ofclaim 1, wherein the inner pad element is arranged in a seat region ofthe bicycle saddle.
 11. The bicycle saddle of claim 1, wherein the innerpad element is arranged in a center region of the bicycle saddle. 12.The bicycle saddle of claim 10, wherein a common inner pad element isarranged in the seat region and in the center region.
 13. The bicyclesaddle of claim 11, wherein the inner pad element arranged in the centerregion is thinner than the inner pad element arranged in the seatregion.
 14. The bicycle saddle of claim 1, wherein the inner pad elementis completely enclosed by the outer pad element and the saddle shell.15. The bicycle saddle of claim 1, wherein a rear region of the innerpad element is not enclosed by an outer pad element.
 16. The bicyclesaddle of claim 15, wherein the rear region of the inner pad element isarranged on a rear side of the saddle shell.
 17. A bicycle saddlecomprising a saddle shell, a saddle frame connected with a lower side ofthe saddle shell, and a saddle pad arranged on an upper side of thesaddle shell, the saddle pad comprising at least two pad elements,wherein a main pad element is connected with the upper side of thesaddle shell, and an auxiliary pad element is arranged in a recess ofthe main pad element.
 18. The bicycle saddle of claim 17, wherein themain pad element has a plurality of recesses in which an auxiliary padelement is arranged, respectively.
 19. The bicycle saddle of claim 17,wherein the auxiliary pad element is arranged in at least one of a seatregion or a center region of the bicycle saddle.
 20. The bicycle saddleof claim 19, wherein the auxiliary pad element arranged in the centerregion is thinner than the auxiliary pad element arranged in the seatregion.
 21. The bicycle saddle of claim 17, wherein the auxiliary padelement is spanned with textile material at least on the outside. 22.The bicycle saddle of claim 17, wherein the auxiliary pad element isglued into the recess.
 23. The bicycle saddle of claim 1, wherein atleast one of the inner pad element or the main pad element comprises atleast one of TPU, EVA, EPP, TPE, EPE, or a combination thereof.
 24. Thebicycle saddle of claim 1, wherein at least one of the outer pad elementor the auxiliary pad element comprises PU-foam.
 25. A saddle pad for abicycle saddle of claim 1, wherein the saddle pad comprises at least onepad element made of at least one of TPU, EVA, EPP, TPE, or EPE, and atleast one pad element made of a foamable material.
 26. The saddle pad ofclaim 24, wherein an inner pad element comprising at least one of TPU,EVA, EPP, TPE, or EPE is enclosed by an outer pad element which is madeof foamed material.
 27. A bicycle saddle comprising a saddle shell, asaddle frame connected with a lower side of the saddle shell, and asaddle pad arranged on an upper side of the saddle shell, the saddle padcomprising at least two pad elements, wherein at least one of the padelements comprises at least one of TPU, EVA, EPP, TPE, or EPE, and atleast one of the pad elements comprises a foamable material.
 28. Amethod for producing a bicycle saddle of claim 1, comprising the stepsof: fastening an inner pad element on an upper side of the saddle shell,placing the saddle shell into a casting mold, and introducing materialinto the casting mold to form an outer pad element.
 29. The method ofclaim 28, wherein the material for forming the outer pad element isfoamed.
 30. The method of claim 28, wherein the inner pad element isprefabricated.
 31. The method of claim 28, wherein the inner pad elementcomprises a retaining protrusion pressed into a recess of the saddleshell to fasten the inner pad element.
 32. The method of claim 28,wherein the saddle shell is placed into the casting mold with the upperside directed downward.
 33. The method of claim 28, wherein prior toplacing the saddle shell into the casting mold, a saddle cover is placedinto the casting mold and is retained in the casting mold.
 34. A methodfor producing a saddle pad of claim 25, comprising the steps of:fastening a first pad element made of at least one of TPU, EVA, EPP,TPE, or EPE in a mold, and introducing a foamed material into the moldto form a second pad element.
 35. The method of claim 34, wherein thefirst pad element is clamped in the mold.
 36. The method of claim 34,wherein the first pad element is prefabricated.